Sole structure with complex waterproof and gas-permeable material and manufacturing method thereof

ABSTRACT

A sole structure with complex waterproof and gas-permeable material and a manufacturing method thereof. A plane blank having a through with a pattern of an array is provided. At least one waterproof and gas-permeable film is combined with the plane blank to cover the through hole. The plane blank with the film is located in a predetermined position inside a sole mold. Then a molten plastic material is filled into the mold to associate the plane blank and the film with the plastic material to form an integral large substrate of the sole. The sole provides waterproof and gas-permeable effect to prevent water from tarrying between the large substrate and middle substrate.

BACKGROUND OF THE INVENTION

The present invention is related to a waterproof and gas-permeable sole structure and a manufacturing method thereof, and more particularly to an improved sole structure which overcomes the problem that the vapor tarries between the large substrate and the middle substrate (or insole) of the conventional gas-permeable shoe.

The conventional waterproof gas-permeable film such as Gore-Tex film (so-called century fabric) is composed of two kinds of unique polymers. One of the polymers is a nearly thermoplastic polyurethane (TPU) material which provides high stiffness. The other is ePTFE which provides waterproof and gas-permeable effect. Nine billion micro-voids are distributed over each square inch area of such material. The size of such void is two hundred millionth the size of liquid water molecule. However, the size of such void is seven hundred times the size of vapor. Therefore, the water molecule cannot pass through the voids, while the vapor is permitted to be exhausted through the voids. The waterproof gas-permeable film such as Gore-Tex can be attached to inner side of nylon and other fabric for making clothes, shoes, gloves, etc. to achieve windproof, waterproof and gas-permeable characteristics. A user wearing such clothes or shoes can keep dry, warm and comfortable.

FIG. 1 shows that the waterproof gas-permeable film such as Gore-Tex is adhered to inner side of a sole for waterproof effect and exhaustion of vapor to keep a user's feet dry. The sole 10 includes a large substrate 11, a middle substrate 12 connected on the large substrate 11 and an insole 13 overlaid on the middle substrate 12. The large substrate 11 is generally made of thermoplastic rubber (TPR) material which is cheaper. Alternatively, the large substrate 11 can be made of TPU or PVC. In the conventional measure, the Gore-Tex has a characteristic closer to that of TPU so that the Gore-Tex can hardly combined with TPR material. Therefore, in manufacturing, the more expensive waterproof and gas-permeable film 40 is adhered between the large substrate 11 and the middle substrate 12 to prevent the water from entering the middle substrate 12 and the insole 13. As known by those skilled in this field, in actual use, although the vapor is isolated from the inner layer of the shoe, the water still often remains between the large substrate 11 and the middle substrate 12 in the positions as shown by the arrows of FIG. 1. This makes a user feel uncomfortable. Moreover, in use of the shoe, the sole will bear great bending force and impact. Therefore, it is quite hard to combine the materials with each other with glue.

In the above structure, the waterproof and gas-permeable film 40 is adhered to the sole 10 to isolation of water and exhaustion of vapor of a user's feet. However, such structure fails to overcome the problem that the water tarries between the large substrate 11 and the middle substrate 12. The melting point of the large substrate 11 is about 180° C. The melting point of the waterproof and gas-permeable film 40 is about 120° C. In addition, these two materials are incompatible with each other. As a result, during the molding procedure, when filling the material of higher temperature into the sole, the waterproof and gas-permeable film 40 is often previously molten or unexpectedly damaged. Therefore, it is hard to associate the waterproof and gas-permeable film 40 with the large substrate 11. This obstructs the waterproof and gas-permeable film 40 from successfully associating with the large substrate 11.

SUMMARY OF THE INVENTION

It is therefore a primary object of the present invention to provide a sole structure with complex waterproof and gas-permeable material and a manufacturing method thereof. The sole provides waterproof and gas-permeable effect to prevent water from tarrying between the large substrate and middle substrate of the sole. A plane blank having a through with a pattern of an array is provided. A waterproof and gas-permeable film made of a material identical to or compatible with the material of the plane blank is combined with the plane blank to cover the through hole. The plane blank with the film is located in a predetermined position inside a sole mold. Then a molten plastic material is filled into the mold to associate the plane blank and the film with the plastic material to form an integral sole.

According to the above object, the sole structure includes a large substrate and a middle substrate overlaid on an inner face of the large substrate. The plane blank combined with the waterproof and gas-permeable film is disposed in a predetermined position on inner face of the large substrate. The water on outer side of the large substrate is isolated and prevented from getting into the shoe through the through hole of the large substrate. However, the air can pass through the waterproof and gas-permeable film into the shoe to achieve gas-permeable and humidity proof effect. The area of the plane blank is larger than that of the film. The molten plastic material at high temperature is fused with the peripheral section of the plane blank. However, by means of a mold core, the plastic material is isolated from the film without contacting and damaging the film.

In the above structure, multiple fixing holes are formed along the peripheries of the plane blank. When the plastic material is filled into the mold, the plastic material can fill into the fixing holes to form a key structure for firmly associating the plane blank with the plastic material.

In addition, a sheet material such as a mesh tissue sheet or porous sheet with high stiffness (such as TPU sheet) is associated with at least one face of the film to reinforce the film and prolong using life of the film.

The present invention can be best understood through the following description and accompanying drawings wherein:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of the sole of a conventional gas-permeable shoe;

FIG. 2 is a perspective exploded view of the sole of the gas-permeable shoe of the present invention;

FIG. 3 is a sectional view according to FIG. 2;

FIG. 4 is a sectional assembled view according to FIG. 3;

FIG. 5 is a bottom view according to FIG. 4;

FIG. 6 is a perspective exploded view of the plane blank, sheet material and film of the present invention, showing the connection relationship thereof;

FIG. 6A is a sectional assembled view according to FIG. 6, showing that the assembly of the plane blank, sheet material and the film is placed in a mold for molding the large substrate of the sole, in which the plastic material is not yet filled into the mold;

FIG. 6B is a view according to FIG. 6A, in which the plastic material is filled into the mold;

FIG. 7 is a perspective exploded view of the plane blank, sheet material and film of the present invention, showing another connection relationship thereof;

FIG. 7A is a perspective exploded view showing that both the upper and lower faces of the film are associated with sheet materials;

FIG. 8 is a sectional assembled view according to FIG. 7, showing that the assembly of FIG. 7 is placed in a mold;

FIG. 8A is an enlarged view of circled area A of FIG. 8;

FIG. 9 is a sectional view according to FIG. 8, showing that the plastic material is filled into the mold; and

FIG. 9A is an enlarged view of circled area A of FIG. 9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Please refer to FIGS. 2 and 3. The sole structure 10 with complex waterproof and gas-permeable material of the present invention includes a large substrate 11. The large substrate 11 can be selectively made of any of TPR, PVC, TPU and the likes. A middle substrate 12 and/or an insole 13 are overlaid on the large substrate 11. A predetermined section of inner face of the large substrate 11 is formed with through holes 14, 15 which can have any geometric profile. The through holes 14, 15 are arranged on front half, rear half or other section of the large substrate 11.

A plane blank 16 combined with waterproof and gas-permeable film 40 is laid on the inner face 111 of the large substrate 11 to correspondingly cover the through holes 14, 15. The plane blank 16 is made of a material identical to or compatible with the material of the waterproof and gas-permeable film 40. The plane blank 16 is formed with an array-type through hole 17 corresponding to the through hole 14 or 15 of the large substrate. In this embodiment, the array-type through hole 17 has an array of multiple oblique slats arranged as a blind. Such array prevents alien articles from directly getting into the shoe through the through hole 17. The film 40 is fixedly combined with the plane blank 16 by means of pressing, high frequency or ultrasonic wave. The film 40 at least covers the through hole 17 of the plane blank 16. In principle, the area of the plane blank 16 is larger than the area of the film 40. In a preferred embodiment, a sheet material 22 such as a mesh tissue sheet or reinforcing sheet made of stiffer material (such as TPU sheet) is associated with at least one surface of the film 40. The sheet material 22 is attached to the film 40. In another embodiment, the position relationship between the film 40 and the sheet material 22 and the number thereof are exchangeable and variable. In other words, the sheet material 22 can be arranged between the large substrate 11 and the film 40 (not shown) or between the film 40 and the middle substrate 12. Alternatively, the sheet material 22 can be laid on both the upper and lower faces of the film 40.

FIGS. 4 and 5 show the improved sole structure to which the plane blank 16 combined with the film 40 is applied. The water on outer face 112 of the large substrate 11 is isolated and prevented from getting into the through hole and tarrying between the inner side of the large substrate 11 and the middle substrate 12. However, the vapor generated by the foot of a user is permitted to be exhausted from the large substrate 11 through the waterproof and gas-permeable film 40 at the through hole 17 of the plane blank 16.

Referring to FIG. 6, the characteristic of the material of the large substrate 11 is different from that of the plane blank 16. Therefore, they may be hard to associate with each other and incompatible. Accordingly, they are associated by a method including step (a), step (b) and step (c). In step (a), a sheet material 22 is laid between the plane blank 16 and the film 40 or on the inner face of the film 40. The sheet material 22 can be stiffer sheet body such as TPU porous sheet densely formed with perforations or mesh tissue sheet. The stiffness of the TPU sheet can reinforce the plane blank 16 or film 40 to resist against intrusion or damage of rocks or other alien articles under the sole.

In step (b), the plane blank 16 associated with the film 40 and the sheet material 22 is located in a predetermined position inside a sole mold 20. An isolating section or pile 21 is used to just cover the peripheral area of the through hole 17 of the blank 16.

In step (c), a plastic (softened) material 30 is filled or placed into the mold 20 for integrally molding the large substrate 11. The plastic material 30 is integrally associated with the periphery of the plane blank 16. In the molding procedure, the plastic material 30 is isolated from the section of the film 40 corresponding to the through hole 17 by the mold 20. Therefore, the plastic material 30 will not contact with or damage the section of the film 40.

In order to solve the problem existing in the prior art that the water tends to tarry inside the large substrate 11 or between the large substrate 11 and the middle substrate 12, the present invention has the following structural characteristics:

-   -   1. The large substrate 11 is formed with through holes 14, 15 in         predetermined positions. A plane blank 16 combined with a film         40 is located on inner surface 111 of the large substrate 11         corresponding to the position of the through hole 14.     -   2. The plane blank 16 is formed with an array-type through hole         17 corresponding to the through hole 14. The film 40 at least         covers the array-type through hole 17, permitting the vapor of         the foot to be exhausted from the large substrate through the         through hole 17 of the film 40. However, the water on outer side         of the sole is isolated by the film 40 and prevented from         getting into the shoe through the sole.     -   3. The area of the plane blank 16 should be larger than that of         the film 40. In step (b), the isolating section or pile 21         presses the plane blank 16 to cover the film 40. Therefore, the         filled high temperature plastic material 30 will flow to         associate with the peripheral area of the plane blank 16, while         the plastic material 30 will not contact with and damage the         section of the film 40 corresponding to the through hole 17.

FIGS. 7, 7A, 8 and 8A show a partially modified embodiment of the present invention. In this embodiment, multiple fixing holes 18, 23 are formed along the periphery of the plane blank 16 or the sheet material 22. When the plastic material 30 is filled into the mold 20, the plastic material 30 can freely flow into the fixing holes 18, 23. Accordingly, an insertion key structure can be formed between the plane blank 16 or sheet material 22 and the plastic material 30 as shown in FIGS. 9 and 9A. The periphery of the sheet material 22 can be also formed with an array fixing holes 23 as the plane blank 16. The fixing holes 23 are aligned with the fixing holes 18 of the plane blank 16. When filling the plastic material 30, the plastic material 30 can be also well associated with the sheet material 22. Accordingly, the large substrate 11, plane blank 16, film 40 and the sheet material 22 can be truly integrally adhered to each other. FIG. 9A shows that after the plastic material 30 enters the fixing holes 18, 23, a part of the plastic material 301 will flow into the space between the bottom of the sheet material 22 and the mold to enclose or combine the plane blank 16, film 40 and sheet material 22 into an integral body by means of the keys. When combined, due to high temperature, the film 40 may be partially molten. After molten, the formed voids is filled up with the plastic material 301. This enhances the binding force for the integral body and prevents the parts of the integral body from detaching from each other when bent. It should be noted that the plane blank 16 can be previously formed with rough surface to enhance the binding force between the plane blank 16 and the plastic material 30. For example, an interface activator or the like can be painted on the surface of the plane blank to clean and roughen the surface thereof. Alternatively, the surface of the plane blank 16 can be directly mechanically roughened to achieve better binding effect.

According to the above arrangement, the present invention can truly solve the problem existing in the conventional sole that the external water gets into shoe through the sole and tarries or accumulates on inner side of the large substrate 11 or between the large substrate 11 and the middle substrate 12.

The above embodiments are only used to illustrate the present invention, not intended to limit the scope thereof. Many modifications of the above embodiments can be made without departing from the spirit of the present invention. 

1. A sole structure with complex waterproof and gas-permeable material, comprising a sole including a large substrate and an insole overlaid on an inner face of the large substrate, said sole structure being characterized in that: the large substrate is formed with at least one through hole; and a plane blank is laid on the inner face of the large substrate, the plane blank being formed with at least one through hole corresponding to the through hole of the large substrate, the plane blank being combined with a waterproof and gas-permeable film at least at the through hole, the plane blank being disposed at the through hole of the large substrate to cover the through hole thereof, whereby the waterproof and gas-permeable film achieves a waterproof and gas-permeable effect.
 2. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein the through hole of the plane blank has a pattern of an array of multiple oblique slats as a blind.
 3. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein a sheet material such as a mesh tissue sheet or porous sheet with high stiffness is associated with at least one face of the waterproof and gas-permeable film.
 4. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein a sheet material such as a mesh tissue sheet or porous sheet with high stiffness is associated with at least one face of the waterproof and gas-permeable film.
 5. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein a sheet material such as a mesh tissue sheet or porous sheet with high stiffness is associated between the waterproof and gas-permeable film and the plane blank.
 6. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein a sheet material such as a mesh tissue sheet or porous sheet with high stiffness is associated between the waterproof and gas-permeable film and the plane blank.
 7. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein the waterproof and gas-permeable film is made of TPU material.
 8. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein the waterproof and gas-permeable film is made of TPU material.
 9. The sole structure with complex waterproof and gas-permeable material as claimed in claim 3, wherein the waterproof and gas-permeable film is made of TPU material.
 10. The sole structure with complex waterproof and gas-permeable material as claimed in claim 4, wherein the waterproof and gas-permeable film is made of TPU material.
 11. The sole structure with complex waterproof and gas-permeable material as claimed in claim 5, wherein the waterproof and gas-permeable film is made of TPU material.
 12. The sole structure with complex waterproof and gas-permeable material as claimed in claim 6, wherein the waterproof and gas-permeable film is made of TPU material.
 13. The sole structure with complex waterproof and gas-permeable material as claimed in claim 3, wherein the porous sheet with high stiffness is made of TPU material.
 14. The sole structure with complex waterproof and gas-permeable material as claimed in claim 4, wherein the porous sheet with high stiffness is made of TPU material.
 15. The sole structure with complex waterproof and gas-permeable material as claimed in claim 5, wherein the porous sheet with high stiffness is made of TPU material.
 16. The sole structure with complex waterproof and gas-permeable material as claimed in claim 6, wherein the porous sheet with high stiffness is made of TPU material.
 17. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein two faces of the plane blank are respectively associated with mesh tissue sheet and porous sheet with high stiffness.
 18. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein two faces of the plane blank are respectively associated with mesh tissue sheet and porous sheet with high stiffness.
 19. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
 20. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
 21. The sole structure with complex waterproof and gas-permeable material as claimed in claim 3, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
 22. The sole structure with complex waterproof and gas-permeable material as claimed in claim 4, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
 23. The sole structure with complex waterproof and gas-permeable material as claimed in claim 5, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
 24. The sole structure with complex waterproof and gas-permeable material as claimed in claim 6, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
 25. The sole structure with complex waterproof and gas-permeable material as claimed in claim 7, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
 26. The sole structure with complex waterproof and gas-permeable material as claimed in claim 8, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
 27. The sole structure with complex waterproof and gas-permeable material as claimed in claim 17, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
 28. The sole structure with complex waterproof and gas-permeable material as claimed in claim 18, wherein the waterproof and gas-permeable film is combined with the plane blank by means of high frequency or ultrasonic pressing.
 29. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein the through hole of the large substrate is arranged on at least a part of bottom face of the sole.
 30. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein the through hole of the large substrate is arranged on at least a part of bottom face of the sole.
 31. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein a middle substrate is additionally disposed between the large substrate and the insole.
 32. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein a middle substrate is additionally disposed between the large substrate and the insole.
 33. The sole structure with complex waterproof and gas-permeable material as claimed in claim 3, wherein a middle substrate is additionally disposed between the large substrate and the insole.
 34. The sole structure with complex waterproof and gas-permeable material as claimed in claim 4, wherein a middle substrate is additionally disposed between the large substrate and the insole.
 35. The sole structure with complex waterproof and gas-permeable material as claimed in claim 5, wherein a middle substrate is additionally disposed between the large substrate and the insole.
 36. The sole structure with complex waterproof and gas-permeable material as claimed in claim 6, wherein a middle substrate is additionally disposed between the large substrate and the insole.
 37. The sole structure with complex waterproof and gas-permeable material as claimed in claim 7, wherein a middle substrate is additionally disposed between the large substrate and the insole.
 38. The sole structure with complex waterproof and gas-permeable material as claimed in claim 8, wherein a middle substrate is additionally disposed between the large substrate and the insole.
 39. The sole structure with complex waterproof and gas-permeable material as claimed in claim 17, wherein a middle substrate is additionally disposed between the large substrate and the insole.
 40. The sole structure with complex waterproof and gas-permeable material as claimed in claim 18, wherein a middle substrate is additionally disposed between the large substrate and the insole.
 41. The sole structure with complex waterproof and gas-permeable material as claimed in claim 1, wherein the peripheral sections of the plane blank and the sheet material are formed with corresponding fixing holes.
 42. The sole structure with complex waterproof and gas-permeable material as claimed in claim 2, wherein the peripheral sections of the plane blank and the sheet material are formed with corresponding fixing holes.
 43. A method for manufacturing a sole structure with complex waterproof and gas-permeable material, comprising steps of: step (a): preparing a plane blank having through hole and combining a waterproof and gas-permeable film with the plane blank, the film at least sealing one side of the through hole; step (b): locating the plane blank in a predetermined position inside a sole mold, an isolating section covering a section of the plane blank fully including the through hole of the blank; and step (c): filling a plastic material into the mold, the plastic material being integrally associated with the periphery of the plane blank, which is free from the isolation of the isolating section to form an integral large substrate.
 44. The method for manufacturing a sole structure with complex waterproof and gas-permeable material as claimed in claim 43, wherein the through hole of the plane blank has a pattern of an array.
 45. The method for manufacturing a sole structure with complex waterproof and gas-permeable material as claimed in claim 44, wherein the film at least covers the through hole with array pattern of the plane blank.
 46. The method for manufacturing a sole structure with complex waterproof and gas-permeable material as claimed in claim 43, wherein in step (a), a porous sheet material is overlaid on the plane blank.
 47. The method for manufacturing a sole structure with complex waterproof and gas-permeable material as claimed in claim 46, wherein the porous sheet material is associated between the plane blank and the film.
 48. The method for manufacturing a sole structure with complex waterproof and gas-permeable material as claimed in claim 46, wherein the porous sheet material is associated with upper and lower sides of the film.
 49. The method for manufacturing a sole structure with complex waterproof and gas-permeable material as claimed in claim 43, wherein the isolating section just covers the through hole of the plane blank.
 50. The method for manufacturing a sole structure with complex waterproof and gas-permeable material as claimed in claim 43, wherein multiple fixing holes are formed along the peripheries of the plane blank and the sheet material combined with the film, whereby when the plastic material is filled into the mold, the plastic material can fill into the fixing holes to firmly associate the plane blank, film and sheet material. 